ROLASTAR Factory Fabricated Ducts

4-Bolt Flange System

ROLA-TDF
(Rolled on Type)

ROLAMATE
(Slip on Type)

Leadership in Ducting

TM

Why Rolastar Ducts ?

Ultra Low Leakage

Quick Installation

Highest Strength to Weight Ratio

Four Manufacturing Plants All Over India

High Energy Saving

Nationwide Sales & Support

Leakage Test Facilities

Most Cost Effective Solution

Air Leakage Test Results

Leakage in CFM

Test
Pressure

Class

w.g.

Max. Permissible

ROLAMATE TM

TDF

24

15.3

2.0 - 3.5

4.0 - 7.0

9.0 -12.0

1 w.g.

24

24.0

3.0 - 6.0

7.0 -11.0

19.0 - 22.0

2 w.g.

24

37.7

8.0 -12.0

12.0 -18.0

30.0 - 36.0
(with sealant)

3 w.g.

12

24.5

10.0 -16.0

15.0 - 22.0

NA

6 w.g.

19.2

14.0 -18.0

NA

NA

10 w.g.

26.8

18.0 - 24.0

NA

NA

Slip & Drive Cleats

Notes:
* As per SMACNA Air Duct Leakage Test Manual
* Tests conducted in-house with high efficiency Air Duct Leakage Tester
* For test ducts of surface area of 100 Square feet.

Comparison
ROLAMATE TM

TDF

Angle Iron

Cleats / G.I. Flanges

Strength-to-weight ration
Installation speed

Low leakage / Energy saving

rd

3 party testing and certification

Environment friendly

Not Available

Not Available

Not Available

Yes

No (+)

Yes

Yes

Damage resistance in transportation

Overall cost effectiveness
(+) Red-oxide is a suspected carcinogen
-2-

Recommended SMACNA Standard at 4 Feet Transverse Joint Reinforcement

ROLASTAR STANDARD
For Selection of TDF / ROLAMATE Duct Gauges for 4 Feet Spacing

Duct Pressure in Inches / (Pascals)

Duct
Dimension

1"(250)*

2"(500)**

3"(750)***

4"(1000)

6"(1500)

10"(2500)

TDF

ROLAMATE

TDF

ROLAMATE

TDF

ROLAMATE

TDF

ROLAMATE

TDF

ROLAMATE

TDF

ROLAMATE

200 - 250

26

26 - F

26

26 - F

26

26 - F

26

26 - F

26

26 - F

26

24 - F

251 - 300

26

26 - F

26

26 - F

26

26 - F

26

26 - F

24

26 - F

24

24 - F

301 - 350

26

26 - F

26

26 - F

26

26 - F

26

26 - F

24

24 - F

24

24 - F

351 - 400

26

26 - F

26

26 - F

26

26 - F

26

26 - F

24

24 - F

22

22 - F

401 - 450

26

26 - F

26

26 - F

26

26 - F

26

24 - F

24

24 - F

20

22 - F

451 - 500

26

26 - F

26

26 - F

24

24 - F

24

24 - F

24

24 - F

20

20 - F

501 - 550

26

26 - F

26

26 - F

24

24 - F

24

24 - F

22

24 - F

20

20 - F

551 - 600

26

26 - F

26

26 - F

24

24 - F

24

24 - F

22

22 - F

20

20 - F

601 - 650

26

26 - F

26

26 - F

24

24 - F

22

24 - F

22

22 - F

18

20 - I

651 - 700

26

26 - F

26

26 - F

24

24 - F

22

24 - F

20

22 - I

18

20 - I

701 - 750

26

26 - F

24

26 - F

24

24 - F

22

24 - F

20

22 - I

18

20 - I

751 - 900

26

26 - F

24

24 - F

22

22 - F

20

22 - I

18

20 - I

18 - JTR

18 - I

901 - 1000

24

26 - F

22

24 - F

20

22 - I

20 - JTR

20 - I

18 - JTR

18 - I

18 - JTR

18 - I

1001 - 1200

24

24 - F

20

22 - I

20 - JTR

20 - I

18 - JTR

18 - I

18 - JTR

18 - I

18 - JTR

18 - I

1201 - 1300

22

24 - F

20 - JTR

20 - I

18 - JTR

18 - I

18 - JTR

18 - I

16 - JTR

16 - J

16 - JTR

16 - J

1301 - 1500

22

24 - F

20 - JTR

18 - I

18 - JTR

18 - I

18 - JTR

16 - I

16 - JTR

1501 - 1800

22 - JTR

22 - I

20 - JTR

18 - I

18 - JTR

16 - J

16 - JTR

16 - I
(JTR)

1801 - 2100

20 - JTR

20 - I

20 - JTR

18 - J

16 - JTR

16 - J
(JTR)

2101 - 2400

18 - JTR

18 - I

18 - JTR

18 - J

16 - JTR

2401 - 2700

18 - JTR

18 - I

16 - JTR

16 - J
(JTR)

2701 - 3000

16 - JTR

16 - J

in (mm)

Notes:
A higher class flange can always be substituted for a lower class (e.g. Class "J" for Class "H", / Class "H" for Class UE", etc.)
1. SMACNA- Sheet Metal and Air conditioning Contractors' National Association Inc-"HVAC Duct Construction Standards- Metal and Flexible"-2005 (Third Edition), U.S.A.
2. Reading Guide- For duct sizes between, say, 901 mm and 1000 mm, when the pressure class is 1" w.g. static, we require duct gauge of 26 & slip-on connector F. For the same size range but with static
pressure at 6" w.g. duct gauge of 18 & slip-on connector I. For the same range in case of TDF flanges in case of pressure class I" w.g. the gauge should be 24, in case of 6" w.g. the gauge should be 18 g with
TDF flange & with joint tie rod (JTR).
3. Use gasket size 10 mm wide and 4.5 mm thick for ducts up to 2" static pressure in case of slip-on flanges upto rigidity class I and for rigidity class above I use 15 mm wide & 6 mm thick gasket.
Use gasket size of 15 mm wide X 6 mm thick with pressure class 3" w.g static and above.
4. Cleats should be fixed at max. 150 mm distance from corner & the at the center distance of 250 mm for ducts up to 3" w.g. static. For more than 3" w.g. static the center distance should not exceed 150
mm.
5. (Not applicable to current specification)
For non-critical comfort cooling applications (1" w.g. pressure class), optional "C & S" or "C & SS" cleat joints can be used.
Upto 450 mm duct size use "C & S'' cleats.
451 to 750 mm duct size use "C & SS" cleats.
Over 750 mm duct size use Rolamate flanges or Rolastar TDF system.
6. TDF can not be made below 250 mm size of the duct. We suggest to use C & S Cleat instead of TDF.
* For 1" pressure class we can use cleats.
** Cleats not recommended over 1" pressure class but if it must be used then appropriate sealant is required for all applications above 1" w.g.
*** In any event cleats should not be used for applications over 3" w.g.

-3-

ROLAMATE System Components

Slip on Flanges : Roll-formed G.I. Section with embedded
Corners : To be inserted into the hollow we of the slip-on

sealant. Available in different cross-sections to provide a

range of rigidity and strength characteristics.

flange. 4 corner pcs. are required for each rectangular

frame, 8 corner pcs. per joint

Gasket : Self-adhesive, microcellular, cross-linked,

Carriage Bolts with Flanged Nuts : Electro-galvanised,

Poyethylene foam type. (Alternatives : PVC or Neoprene)

square-necked carriage bolts, with flanged nuts, Each joint

required 4 sets.

Flange Testing and Certification :

ROLAMATE Flanges have been designed to meet the appropriate SMACNA -2005 Reinforcement Classes and tested successfully at ROLASTAR

to meet the rigidity and leakage requirement in accordance with both

a) SMACNA testing norms and practices.
b) Benchmarking with leading international 4-Bolt systems.

All tests are carried out with ROLAMATE System Components. Further details on test procedures used at ROLASTAR and third party's laboratory

test results are available from the company upon request.

It is mandatory to use all ROLAMATE system components, specifically Rolastar-supplied gaskets sealants to obtain the desired performance.

-4-

ROLAMATE Assembly Instructions

Cutting Slip-on Flanges
TM

In normal practice, the correctly sized (pre-cut) slip on flanges and exact quantities of the other ROLAMATE System Components are supplied from
the factory to be assembled at site. Where the flanges are supplied in full lengths (usually in 6 m lengths), cutting of these is done at site as follows:
Sr.
No.

Flange Type

ROLAMATE E/F

Flange Cutting Size

TM

(X-29 mm), where X = Duct side dimension

TM

ROLAMATE H/I & J

(X-39 mm), where X = Duct side dimension

TM

"Slice" the blade through the ROLAMATE flange using a metal friction cutting blade. While cutting, the flange should always be gripped with the legs
down to prevent metal cuttings from falling into the integral seal. Cutting by abrasive blade is not recommended due to melting of the mastic by the
heat generated during cutting.

Assembling Frames
2

TM

TM

TM

Step 1 - Insert ROLAMATE corner at each end of the ROLAMATE

flange as shown in fig.1.
(Ensure that the recessed groove of the corner piece
matches with that of the flange).

Step 2 - Form a "U" with two corners and the ROLAMATE flanges
cut for the other two adjacent sides of the duct
sections.
Step 3 - Complete the frame as shown in fig.2.

ROLAMATE Installation Instructions

Mounting of Frame

Start mounting the

Ensure that the

completed frame at
any corner of duct
section (fig.3)

ROLAMATE
corners
completely clear the
duct edges (fig.4)
(i.e. the corner piece
should not sit on the
duct corner edge)

TM

For minor adjustments

Ensure that the duct

to ensure the proper

seating of frames, tap
the corners out slightly
(fig.5)

section reaches right

up to the end of the
ROLAMATE slip-on
flange thus dipping
into the integral
mastic sealant (fig.6)
TM

-5-

Fastening ROLAMATE Frame Section

8

After mounting fasten the frame to the duct section by

i) Clinching Machine (fig.7) (preferred system). Alternatively by

ii) Self tapping screws iii) Pop-riveting or iv) Spot-welding Commence fastening from one corner and proceed around the duct section in one
direction. Locate the first fastener within 20mm from each end of the flange (fig.8) and distribute pitches suitably.

Spacing :
Each side must have a minimum of two fastenings within 20 mm of each end. Maximum spacing between fastenings is 300 mm.

Corner Sealing

After fastening the frame to the duct section, a thin bead of sealant is applied only at the interface of the duct corner edge with the ROLAMATE

corner piece (fig. 9). Applying the sealant as shown in (fig.10) should be avoided as it is unnecessary and results in undue wastage.
9

10

RIGHT WAY

WRONG WAY

Gasketing

Apply the self-adhesive gasket to only one of the mating frames (not both). Ensure that the gasket is properly seated in the groove in the
ROLAMATEflange. Commencing midway between the corners, the gasket is applied in one piece around the ROLAMATEframe and joined at the
starting point in a butt joint (fig. 11). The gasket has to cut over the corners in an arc, protruding slightly into the air stream at the corners (fig. 12).
From consideration of air leakage, the gasket should not contour the duct edge as shown in (fig. 13).
11

RIGHT WAY

12

WRONG WAY

13

Tightening of Bolts & Alignment

The square neck of the carriage bolt facilitates tightening of the nut with one hand using a ratchet (preferred) or spanner. Longer duct lengths can
be aligned by passing a wire through the small round holes on the ROLAMATE corners.

Cleat Installation

For ROLAMATE E/F and H/I flange classes the new ROLAMATE cleat the J class flange, The
ROLAMATE GI cleat must also be crimped using a special crimping tool available from ROLASTAR.
Cleats should be spaced so that the cleat end is within 150mm (6") of each companion flange end
and the pitch between cleats is,
Pressure Class
Pitch Spacing
Upto 750 Pa (3" w.g)
250 mm
Above 750 Pa
150 mm
-6-

14

ROLASTAR - TDF System

Gasket Groove

FLANGE

CORNER

GASKET

DUCT

Gasket Groove

Flange Profile

CLEAT
CARRIAGE BOLT

CLEAT

FLANGED
NUT

DUCT

TDF is a flanging system that consists of forming a flange profile on the duct ends, thus made out of a sheet from which the duct is fabricated. TDF is
a 4 bolt duct connection system that eliminates time wastage. Rather than using separate connectors to assemble your system, TDF flanges are
rollformed onto duct during the manufacturing process. This connection minimizes leakage and installation costs. These TDF flange eliminates the
additional internal sealing around the edges of duct & thereby saves the labour & material.

Features :

Highly accurate flange profiles and components ensure ease of fitting and high quality assembly.

A Recessed groove on flange and radial groove on corner pieces for proper gasket seating.

Snap fit corner pieces to allow easy fitting at sites.

Flexibility to use suit-to-site pieces with ROLAMATE slip-on flanges.

Slip & Drive Cleats System

Slip and Drive Cleats system is generally used for low-end, less-critical
applications. Traditionally, only the Drive cleats ("C") which are positioning
cleats were used for all four sides. This was giving a poor joint. The Slip cleats
("S" / "Standing S") on the alternate opposite sides provide the moderate
rigidity to the joint.
While installing, Drive cleats are always fitted on the shorter sides and Slip
cleats on the longer sides.

C-Cleat

Special Notes :

1. ROLASTAR does not subscribe to usage of red-oxide painted Angle Iron flanges as red-oxide is a known carcinogen.
2. Conventional G.I. flanges have now become obsolete as they are totally substituted by Slip and Drive cleats system.
3. TDF can not be made below 250 mm size of the duct. We suggest to use C & S cleat instead of TDF.
-7-

S-Cleat

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Wipro

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EMC2

IHG

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Yahoo

CICSO

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IT Park

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Mind Tree

Ericsson

VSNL

e- Capital

Airtel Bharti

Pharma & Healthcare

Cipla

Zydus

Panacia Biotech

Glanmark Pharma

Phonex

Himalaya Drugs

Dr. Reddys Lab

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Fortis Hospital

Batra Hospital

Satya Sai Hospital

Apollo Hospital

GBP Hospital

Artemis Hospital

Medi City

Hotels

Leela Hotel

Today Hotel

Lodhi Hotel

Grand Hyatt Hotel

Hyatt Regency Hotel

ITC Hotel

Taj Hotel

Taj Krishna Hotel

ITC Gardenia Hotel

Viceroy Hotel

Indus Hotel

Uppal Hotel

Maurya Sherton

Oberoi Hotel
Industrial

Maruti Udyog

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Reliance Industries

L&T

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HUL

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Lipton

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Coca Cola India Ltd.

Hindustan Zinc

Airports

Government Projects

Delhi Airport

Mangalore Airprot

Madurai Airport

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DMRC

DRDO

Atari Railway Station

Bina Refinary

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Talktora Stadium

Major Dhyanchand Stadium

Indira Gandhi Stadium

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SPM Stadium

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Shopping Malls & Multiplexes

Lulu Mall

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Express Mall

Ascendas Mall

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Celebration Mall

Shipra Mall

Erros Mall

Sikndar Pur Mall

Sahara Mall

Pantallon

Shoppers Stop

Banking

BNP Paribas

HSBC

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ICICI

Institutions

Amity University

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International School of Business

Sri Mata Vaishno Devi Institute

Others

US Embassy

Canada Embassy

Kuwait Embassy

Turkey Embassy

Reliance Corporate Office

Al-Safwa Limited

May & Baker

Corporate Office / Operations

Near Wilhelm Textile Ind., Behrampur Road,
Village Khandsa, Gurgaon-122001, Haryana
Ph : (0124) - 4324800 (30 Lines)
Fax : (0124) - 4324811
E-mail : factory_gurgaon@rolastar.com

Western Region
Bilimora, Gujarat
Ph : (02634) - 284182, 282141, 280796
TeleFax : (02634) - 284639
E-mail : factory@rolastar.com

Southern Region
Bangalore, Karnataka
Ph. : (080) - 23715621 / 22
Fax : (080) - 23715623
Email : factory_bangalore@rolastar.com
Leadership in Ducting
A Tomkins Group Company

Hyderabad, Andhra Pradesh :

Ph. : (08418) - 222033 / 34
Email : factory_hyderabad@rolastar.com

www.rolastar.com